Apparatus for assembling flanges to waveguides

ABSTRACT

Apparatus for assembling flanges to waveguides which utilizes electromagnetic forming means for producing the bond between the waveguide and the flange assembly. The flange assembly includes a collar portion which is mounted about the waveguide adjacent the end thereof and a flanged portion extending from the collar portion. A tapered mandrel is inserted in the waveguide and the electromagnetic forming device is mounted around the collar of the flange assembly and energized for application of a magnetic field across the flange collar and waveguide. A primary varying magnetic field is generated which is which is inductively linked with the workpiece, in this case, the flange collar. The primary varying field induces eddy currents in the collar and the eddy currents create a secondary magnetic field which interacts with the primary field to produce a high uniform pressure which swages the flange assembly against against the waveguide. The mandrel prevents collapse of the flange collar and waveguide during the assembly and is removed subsequent to completion of the assembly.

United States Patent [72] Inventors Albert E. Hlghducheelr Syracuse; Ralph L. Bustn, Scotia, both of, N.Y.; Raymond G. Rushing, Mentor, Ohio [21] Appl. No. 863,865 [22] Filed 06.6,1969 [45] Patented July 6, 1971 {73] Assignee The United States Government [54] APPARATUS FOR ASSEMBLING FLANGES T0 WAVEGUIDES 4 Claims, 6 Drawing Flgs.

[52] US. Cl. 29/203 D, 29/200, 29/421, 29/600, 72/56 [51] Int. Cl "05k 13/00, 823p l9/00;. 323p 17/00 [50] Field 01 Search 29/200 E, 203 D, 421, 200 B, 600; 72/56 [56] References Cited UNITED STATES PATENTS 2,976,907 3/1961 Harvey et a1 72/56 3,106,529 7/1965 Schwinghamer 29/200 3,l96,649 7/ 1965 Furth 29/421 Primary Examiner-Thomas H. Eager Attorneys-Alva l-l. Bandy, Willaim G. Gapcynski, Lawrence A. Neureither, Leonard Flank, Jack W. Voigt and Harold W. Hilton ABSTRACT: Apparatus for assembling flanges to waveguides which utilizes electromagnetic forming means for producing the bond between the waveguide and the flange assembly. The flange assembly includes a collar portion which is mounted about the waveguide adjacent the end thereof and a flanged portion extending from the collar portion. A tapered mandrel is inserted in the waveguide and the electromagnetic forming device is mounted around the collar of the flange assembly and energized for application of a magnetic field across the flange collar and waveguide. A primary varying magnetic field is generated which is which is inductively linked with the workpiece, in this case, the flange collar. The primary varying field induces eddy currents in the collar and the eddy currents create a secondary magnetic field which interacts with the primary field to produce a high uniform pressure which swages the flange assembly against against the waveguide. The mandrel prevents collapse of the flange collar and waveguide during the assembly and is removed subsequent to completion of the assembly.

III I/ APPARATUS FOR ASSEMBLING FLANGES TO WAVEGUIDES BACKGROUND OF THE INVENTION This invention relates to apparatus for assembling flanges to waveguides utilizing an electromagnetic'forming process.

Conventionally, the assembling of flanges to waveguides has been accomplished by mechanical means, such as, brazing, welding, soldering, etc., and by chemical means such as bonding. However, there are many inherent disadvantages in the above mentioned approaches. Forexample, the mechanical process is undesirable in that the process causes a decrease in the tensile strength of the joined sections. Additionally, in the soldering, welding, and brazing process,'many times deformation of materials occurs and results in a time consuming and costly process. The chemical process of bonding flanges to waveguides is undesirable in that many times the components (bonded section) are not uniformly assembled due to the forming of pores during the chemical reaction that leaves the components nonuniformly combined and the process results in a risk of bonding rupture.

In order to overcome the above mentioned undesirable features of devices of the prior art, the apparatus of the present invention provides for the assembly of flanges and waveguides by an electromagnetic forming process that results in a less timely operation, cost reduction of method and apparatus, an overall greater proficiency in the assembly of flanges to waveguides and, also, provides a more durable bonding between the sections.

SUMMARY OF THE INVENTION The apparatus of the present invention includes electromagnetic forming means for application of a work force across a collar of a flange which is mounted about a waveguide. The collar and waveguide are swaged together responsive to application of the electromagnetic force.

It is, therefore, an object of this invention to provide apparatus by which flanges and waveguides may be assembled and bonded by utilizing magnetic forming means.

Other objects and advantages of our invention will be more readily apparent from the following detailed description taken in conjunction with the accompanying drawing:

BRIEF DESCRIPTION OF THE DRAWING FIG. I is a cross-sectional view of a flange as utilized in the present invention.

FIG. 2 is a front view of the flange of FIG. 1.

FIG. 3 is an embodiment of our invention utilizing the thrutype flange of FIG. 1 for assembly to a waveguide.

FIG. 4 is a cross-sectional view of a self-locating flange utilized in another embodiment of our invention.

FIG. 5 is a front view of the flange of FIG. 4.

FIG. 6 is an embodiment of our invention utilizing the selflocation flange of FIG. 4 for assembly to a waveguide.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to FIG. 3, apparatus 10 of the preferred embodiment of our invention includes a tapered mandrel element 12 that is adapted for insertion into a waveguide I4. A thru-type flange assembly 16 having a collar portion 20 and a flange portion 22 as shown in FIGS. 1 and 2, is positioned over the outer surface of one end of waveguide 14. A field shaper l5 and a coil 18 is carried around the outer surface of the flange collar portion 20 and adjacent to flange portion 22. The forming coil, upon energization thereof, produces a magnetic field which provides a force which is directed to the collar for swaging the flange assembly to the waveguide.

Pulsed magnetic pressures of a predetermined magnitude are applied for a predetermined period of time and the magnetic pressures, produced by electrical energy that is stored and released through coil 18 establishes a ma netic field that is directed to flange assembly 10. The induce currents react with the coil field that provides a force on the flange thereby swaging the flange to the waveguide. The tapered mandrel 12 may be extracted, after the swaging is accomplished, if desired.

Referring now to FIGS. 36, there is shown another embodiment of our invention, wherein like numerals refer to like parts. This embodiment provides for a flange assembly 24 having a self-locating means. As shown in FIG. 6, tapered mandrel element 12 is adapted for insertion into waveguide 14. A selflocating flange assembly 24 is provided with a collar 28 having an internal annular shoulder 26 against which an end of the waveguide abuts responsive to insertion of the waveguide in the flange. Field shaper I5 is carried about the outer peripheral surface of the collar 28 and adjacent to a flange portion 30 of assembly 24. whereupon activation of the magnetic forming coil as discussed supra, provides sufficient pressure for swaging the flange to the waveguide, this pressure is directed to the collar by the field shaper.

The magnetic field, in the above described device, may be generated by discharging a bank of capacitors across the coils. Upon energization of the coils, a uniform force is applied and concentrated to the selected area to swage the flange assembly to the waveguide.

I claim:

1. Apparatus for assembling flanges to waveguides compris ing:

a. a flange assembly including a collar having a flanged portion extending therefrom;

b. a core element adapted for insertion into said waveguide;

c. electromagnetic forming means carried about said collar of said flange adjacent said flanged portion thereof, said forming means disposed for energization for applying a work force between said core element and said neck for swaging said flange collar to said waveguide.

2. Apparatus in claim 1 wherein said! electromagnetic means includes: I

a. a coil disposed about said collar;

b. means for applying electrical energy through said coil,

said energy disposed for providing a force across said collar and said waveguide of a magnitude sufficient to swage said collar to said waveguide.

3. Apparatus in claim 2 wherein said core element provides support means for said waveguide to prevent collapse thereof responsive to application of said forces, said core element being tapered for ease of removal subsequent to the swaging.

4. Apparatus in claim 3 wherein said. flange includes a collar portion having an internal annular shoulder disposed for abutting relationship with one end of said waveguide to serve as a seat therefor. 

1. Apparatus for assembling flanges to waveguides comprising: a. a flange assembly including a collar having a flanged portion extending therefrom; b. a core element adapted for insertion into said waveguide; c. electromagnetic forming means carried about said collar of said flange adjacent said flanged portion thereof, said forming means disposed for energization for applying a work force between said core element and said neck for swaging said flange collar to said waveguide.
 2. Apparatus in claim 1 wherein said electromagnetic means includes: a. a coil disposed about said collar; b. means for applying electrical energy through said coil, said energy disposed for providing a force across said collar and said waveguide of a magnitude sufficient to swage said collar to said waveguide.
 3. Apparatus in claim 2 wherein said core element provides support means for said waveguide to prevent collapse thereof responsive to application of said forces, said core element being tapered for ease of removal subsequent to the swaging.
 4. Apparatus in claim 3 wherein said flange includes a collar portion having an internal annular shoulder disPosed for abutting relationship with one end of said waveguide to serve as a seat therefor. 